Mobile water filtration system

ABSTRACT

Mobile water filtration enables on-site recycling of wastewater for reuse in mechanical decoking operations of fired-heaters, furnaces, boilers, or systems prone to build up of deposits, residue, or scale and enables on-site disposal of wastewater in a safe and environmentally conscious manner. In batch operations, a coagulant, a flocculant, and a plurality of cascaded filters of increasingly fine pitch may be used to treat wastewater and remove particulate matter, such as, for example, coke, for reuse or safe disposal. In continuous operations, a plurality of cascaded filters of increasingly fine pitch may be used. A control system may be used to automate the operation of a mobile water filtration system for use with a decoking system, such that it does not require human intervention exception for maintenance operations related to filters. The filtered water may be disposed of on-site, eliminating the need for further treatment or transport off site.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of PCT International ApplicationPCT/US2020/051152, filed on Sep. 17, 2020, which is hereby incorporatedby reference in its entirety for all purposes.

BACKGROUND OF THE INVENTION

Raw coke is a product or byproduct that is created by heating coal orcrude oil in the absence of air. While the resulting composition mayvary based on the feedstock, raw coke is a carbon-rich material withlittle to no entrained gas that may be further processed into anindustrial fuel or raw material for other manufacturing processes. Inrefinery coking operations, residual oils, sometimes referred to asbottoms from the atmospheric or vacuum distillation columns, areintentionally converted into petroleum coke and byproducts by a cokingprocess that thermally splits the long chain hydrocarbons of thefeedstock into shorter chain hydrocarbons. However, it is theunintentional creation of coke as a residue or scale in fired heatersand boilers that is problematic to the ongoing operation of the firedheater or boiler.

A fired heater is typically a direct-fired heat exchanger that raisesthe temperature of fluids flowing through one or more tubular coilsdisposed therein. In refinery applications, fired heaters are used inthe crude distillation and vacuum distillation columns. When oil flowsthrough the tubes of the heater, the oil starts to vaporize andasphaltenes precipitate out, forming a coke residue. As coke depositsbuilds up on the inside of the tubes, the coke burns intensely, raisingthe temperature and creating a hot spot within the heater. Consequently,the temperature of the fired heater must be reduced to compensate forthe heat contribution of the hot spots, otherwise the metal temperaturesof the tubes will increase to a metallurgical limit and damage thesystem. When coke deposits build up, the fired heater must be shut downand the tubes must be decoked to remove the residue or scale from withintheir lumen, thereby restoring the capability of the fired heater toachieve the required temperature for proper operation. While there areseveral factors that influence the formation of coke, some of which maybe mitigated to some extent, the formation of coke is unavoidable andfired heaters and boilers require removal of coke deposits as a regularpart of maintenance operations.

BRIEF SUMMARY OF THE INVENTION

According to one aspect of one or more embodiments of the presentinvention, a method of mobile water filtration for on-site decokingoperations includes monitoring a fluid volume of a first tank and afluid volume of a second tank, if the fluid volume of the first tank isless than a first predetermined volume, starting a first pumping systemto fluidly communicate fluids from an inlet connector to the firstpumping system, a first filtration system, and the first tank andstopping a second pumping system, if the fluid volume of the first tankreaches a second predetermined volume, fluidly communicating apredetermined volume of coagulant into the first tank, if the fluidvolume of the first tank reaches a third predetermined volume, fluidlycommunicating a predetermined volume of flocculant into the first tank,pausing for a predetermined amount of time to allow the first tank tosettle, and starting the second pumping system to fluidly communicatefluids from the first tank to a second filtration system and the secondtank, if the fluid volume of the second tank reaches a fourthpredetermined volume, starting a third pumping system to fluidlycommunicate fluids from the second tank to a third filtration system, afourth filtration, and an outlet connector, and if the fluid volume ofthe second tank reaches a fifth predetermined volume, stopping thesecond pumping system.

According to one aspect of one or more embodiments of the presentinvention, a mobile water filtration system for on-site decokingoperations includes a mobile trailer having an inlet connector and anoutlet connector. The system further includes a first pumping system, afirst filtration system, and a first tank disposed in the mobiletrailer, where the inlet connector is fluidly connected to an inlet ofthe first pumping system, an outlet of the first pumping system isfluidly connected to an inlet of the first filtration system, and anoutlet of the first filtration system is fluidly connected to an inletof the first tank. The system further includes a second pumping system,a second filtration system, and a second tank disposed in the mobiletrailer, where an outlet of the first tank is fluidly connected to aninlet of the second pumping system, an outlet of the second pumpingsystem is fluidly connected to an inlet of the second filtration system,and an outlet of the second filtration system is fluidly connected to aninlet of the second tank. The system further includes a third pumpingsystem, a third filtration system, and a fourth filtration systemdisposed in the mobile trailer, where an outlet of the second tank isfluidly connected to an inlet of the third pumping system, an outlet ofthe third pumping system is fluidly connected to an inlet of the thirdfiltration system, an outlet of the third filtration system is fluidlyconnected to an inlet of the fourth filtration system, and an outlet ofthe fourth filtration system is fluidly connected to the outletconnector. A control system that controls a pump speed of the firstpumping system, the second pumping system, and the third pumping system.

Other aspects of the present invention will be apparent from thefollowing description and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a conventional fired heater connected to a mobile decokingsystem.

FIG. 2A shows a rear-facing perspective interior view of a mobile waterfiltration system in accordance with one or more embodiments of thepresent invention.

FIG. 2B shows a front-facing perspective interior view of a mobile waterfiltration system in accordance with one or more embodiments of thepresent invention.

FIG. 2C shows a top plan interior view of a mobile water filtrationsystem in accordance with one or more embodiments of the presentinvention.

FIG. 3A shows a top plan exploded view of a mobile water filtrationsystem in accordance with one or more embodiments of the presentinvention.

FIG. 3B shows a rear-facing perspective exploded view of a mobile waterfiltration system in accordance with one or more embodiments of thepresent invention.

FIG. 3C shows a front-facing perspective exploded view of a mobile waterfiltration system in accordance with one or more embodiments of thepresent invention.

FIG. 4A shows a rear-facing perspective view of a first pumping system,first filtration system, second pumping system, and second filtrationsystem of a mobile water filtration system in accordance with one ormore embodiments of the present invention.

FIG. 4B shows a top plan view of a first pumping system, firstfiltration system, second pumping system, and second filtration systemof a mobile water filtration system in accordance with one or moreembodiments of the present invention.

FIG. 4C shows a front-facing perspective view of a third pumping system,third filtration system, and fourth filtration system of a mobile waterfiltration system in accordance with one or more embodiments of thepresent invention.

FIG. 4D shows a top plan view of a third pumping system, thirdfiltration system, and fourth filtration system of a mobile waterfiltration system in accordance with one or more embodiments of thepresent invention.

FIG. 5 shows a block diagram of a mobile water filtration system inaccordance with one or more embodiments of the present invention.

FIG. 6A shows a batch method of mobile water filtration in accordancewith one or more embodiments of the present invention.

FIG. 6B shows a method of mobile water filtration in accordance with oneor more embodiments of the present invention.

FIG. 6C shows a method of mobile water filtration in accordance with oneor more embodiments of the present invention.

FIG. 7 shows a programmable logic controller (“PLC”) based controlsystem of a mobile water filtration system in accordance with one ormore embodiments of the present invention.

FIG. 8 shows an exemplary application of a mobile water filtrationsystem disposed on-site supporting decoking operations of a fired heaterin accordance with one or more embodiments of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

One or more embodiments of the present invention are described in detailwith reference to the accompanying figures. For consistency, likeelements in the various figures are denoted by like reference numerals.In the following detailed description of the present invention, specificdetails are set forth to provide a thorough understanding of the presentinvention. In other instances, well-known features to those of ordinaryskill in the art are not described to avoid obscuring the description ofthe present invention.

Decoking is the process of removing undesired coke deposits from withinthe lumen of the tubular coil or coils of fired heaters or boilers.While there are a number of methods to decoke a fired heater or boiler,the means and effectiveness of the methods vary. The steam-air decokingmethod uses a mixture of steam, air, and heat to shrink and crack thecoke deposits. The steam and air mixture passes through the cokedeposits inside the tubes while the tubes are heated externally. Whilethis method is somewhat effective for the radiant tubes, it is largelyineffective at removing coke deposits from within the convection tubes.If the steam-air method fails, it may become necessary to dismantle thetubing in an expensive, time consuming, and potentially destructivemethod of cleaning. Another disadvantage to the steam-air method is thatthe chemical reaction between steam, air, and the coke deposits producesgases such as CO, CO₂, and H₂ that must be vented to the atmosphere andare considered bad for the environment.

The inline-spalling decoking method is unique in that it is the onlydecoking method that may be carried out while the fired heater remainsin service. One furnace at a time may be treated while the others remainin operation. The inline-spalling method passes high velocity steam,which is alternately heated and cooled, through the tubes deliveringthermal shocks to spall coke deposits off the walls of the tubes. Whilethe inline spalling method is more environmentally friendly than thesteam-air method, additional decoking may be required since theinline-spalling method is well known to not fully decoke the radianttubes and is also largely ineffective at removing coke deposits fromwithin the convection tubes. Another disadvantage to the inline-spallingdecoking method is that the tubes are prone to damage from repeatedcontraction and expansion during spalling. The chemical decoking methodcirculates a chemical cleaner, usually an acid, through the tubes untilthe coke deposits have been sufficiently loosened for removal. The tubesare then flushed with water to remove the deposits from within the coil.During the flushing process, the chloride content of the water must beclosely monitored, otherwise the inner walls of the tubes may be proneto corrosion. Another disadvantage to the chemical decoking method isthat the chemicals used to decoke the tubes are not environmentallyfriendly, so they must be captured and disposed of in accordance withenvironmental regulations, which further increases decoking costs.

Mechanical decoking has proven to be the most effective method ofremoving coke deposits from within the tubes of fired heaters orboilers. Mechanical pigs are propelled through each tubular coil,typically from end to end, to dislodge and remove coke deposits frominside the tubes. While a variety of mechanical pigs are commerciallyavailable, studded pigs have proven effective at removing coke deposits.A mobile pumping unit propels one or more pigs through the tubes in abi-directional manner to remove coke deposits in a wire-brush likemanner. In addition, these pigs are capable of navigating plug headerseasily without modification to the tubes. As such, mechanical decokinghas proven more effective at removing coke deposits and advantageouslydoes not vent gases to the atmosphere, does not expose the tubes torepeated contraction and expansion, and does not require the use ofacids or chemicals that require reclamation. In addition, mechanicaldecoking is a faster cleaning process that provides comparatively longerrun lengths with respect to other cleaning processes.

FIG. 1 shows a conventional fired heater 100 connected to a mobiledecoking system 105 for mechanical decoking operations. While a firedheater 100 is shown for purposes of illustration only, one of ordinaryskill in the art will appreciate that the discussion that followsapplies to any type or kind of system, including fired heaters,furnaces, boilers, and any other system that use tubulars subject to thebuildup of residue or scale. The exemplary fired heater 100 may includea radiant heating chamber 110 and a convection heating area 115. Duringrefinery operations, the radiant heating chamber 110 may be used toprocess fluids (not shown) that are fluidly communicated from theradiant tubing inlet 120 to the radiant tubing outlet 125 via a tubularcoil 130 comprised of a plurality of radiant tubes (not independentlylabeled). A plurality of fired burners 135 or other heating elements maybe disposed within the radiant heating chamber 110, providing radiantheat to the process fluids (not shown) as they traverse the tubular coil130. Similarly, the convection heating area 115 may be used to processfluids (not shown) that are communicated from the convection tubinginlet 140 to the convection tubing outlet 145 via a tubular coil 150comprised of a plurality of convection tubes (not independentlylabeled). Convection may be used to heat the process fluids (not shown)traversing the tubular coil 150 of convection tubes.

As coke residue builds up within the lumen, or interior passageway, ofone or more of tubular coils 130 or 150, the deposits burn intensely,raising the temperature at that location and creating a hot spot (notshown) within the fired heater 100. Consequently, the temperature of thefired heater 100 must be reduced in view of the heat contribution of thehot spots, to prevent the temperature of the metal tubes 130 or 150 fromincreasing to, or exceeding, their metallurgical limit. Once sufficientdeposits have built up, the fired heater 100 must be shut down anddecoking operations must be performed to dislodge and flush the cokedeposits from within the tubes 130 or 150, thereby restoring thecapability of the fired heater 100 to achieve the required temperaturefor proper operation

A mobile decoking system 105, such as that commercially offered byCokebusters® USA Inc., of Houston, Tex., may be disposed on-site of thefired heater 100 to mechanically decoke the radiant tubes 130 and/orconvection tubes 150. The mobile decoking system 105 may include asource water inlet 155 to a clean water tank (not shown) that receivessource water (not shown) that may be provided on-site by the operator ofthe fired heater 100 and a wastewater outlet 160 that outputs wastewater(not shown) produced by the mechanical decoking process, the disposal ofwhich is discussed in more detail herein, from the dirty water tank (notshown). The mobile decoking system 105 may include a pump system (notshown) that fluidly communicates source water (not shown) from thesource water outlet 165 to the radiant tubing inlet 120 via a conduit170. The radiant tubing outlet 125 may fluidly communicate coke-ladenwastewater (not shown) to the wastewater inlet 175 of the mobiledecoking system 105 via a conduit 180. Similarly, the mobile decokingsystem 105 may include a pump system (not shown) that fluidlycommunicates source water (not shown) from the source water outlet 185to the convection tubing inlet 140 via a conduit 190. The convectiontubing outlet 145 may fluidly communicate coke-laden wastewater (notshown) to the wastewater inlet 195 of the mobile decoking system 105 viaa conduit 197.

While not shown, a mechanical pig (not shown), such as, for example, ascraper, studded, brush, or any other type or kind of pig may bedisposed in the fluid path within the lumen of the tubular coils 130and/or 150. The pump system (not shown) of the mobile decoking system105 may pump source water (not shown) to propel the pig (not shown)through the tubes 130 or 150. Valves (not shown) on either side of thefluid flow path may be advantageously used, in addition to theapplication of fluid pressure, to propel the pig (not shown) in aunidirectional or bi-directional manner. As the pig (not shown)traverses the tubes 130 or 150 under fluid pressure, the dislodgedresidue or scale may be flushed from the tubing 130 or 150 with thesource water (not shown) flowing therethrough, forming what is referredto as coke-laden wastewater (not shown) due to the fact that it includesdislodged coke from the tubes 130 or 150. Due to the size, shape, andcomplexity of the tubes 130 or 150, which may vary from application toapplication, the volume of water required to fully decoke the firedheater 100 is voluminous. The wastewater (not shown) generated, isequally voluminous, and includes coke, residue, and scale that must bedisposed of in a safe and environmentally conscious manner. While themobile decoking system 105 removes substantive portions of visible cokeprior to discharging the wastewater (not shown) out of the wastewateroutlet 160, the wastewater (not shown) that is discharged from themobile decoking system 105 remains contaminated by coke, is not suitablefor reuse, and is not suitable for discharge on-site for environmentalreasons.

While the mechanical decoking method has proven to be the most effectiveand favored method of decoking in the industry, it too presents a numberof challenges. Specifically, a voluminous amount of source water isrequired on-site to fully decoke the fired heater producing asubstantially equal volume of wastewater, containing dislodged coke,deposits, residue, or scale, that must be dealt with. While it is anabsolute requirement to decoke on-site, the coke-laden wastewater istypically stored during decoking operations and then transported offsite for further processing or disposed of on-site in a safe andenvironmentally conscious manner. As such, mechanical decoking requiresadditional on-site storage and in applications where wastewater istransported off site, additional trucking resources. Thus, thesubstantial volume of source water required on-site, and thesubstantially equal volume of wastewater produced are significantdrivers of cost in decoking operations. Notwithstanding, decokingoperations are a necessity required as part of regular maintenance ofthe fired heater.

Accordingly, in one or more embodiments of the present invention,methods of, and systems for, mobile water filtration enables on-siterecycling of wastewater for reuse in, for example, mechanical decokingoperations of fired-heaters, furnaces, boilers, or other systems proneto build up of deposits, residue, or scale and enables on-site disposalof wastewater in a safe and environmentally conscious manner. In certainbatching embodiments, a coagulant, a flocculant, and a plurality ofcascaded filters of increasingly fine pitch may be used to treatwastewater and remove particulate matter, such as, for example, coke,for reuse or safe disposal. In certain continuous embodiments, aplurality of cascaded filters of increasingly fine pitch may be used totreat wastewater and remove particulate matter. In addition, operationsmay be automated for use with a decoking system in a manner that doesnot require human intervention except for maintenance operationsrelating to filters. Advantageously, the volume of source water requiredfor mechanical decoking operations is significantly reduced and thevolume of wastewater produced is substantially reduced as a consequence.In addition, the filtered water exiting the mobile water filtrationsystem may be disposed of on-site in a safe and environmentallyconscious manner, thereby reducing or eliminating the need for furthertreatment or transport off site for further treatment and disposal.Because of the significant reduction in the volume of water required tobe sourced for mechanical decoking operations and the ability to safelydispose filtered water after completion of operations on-site, themethod and system significantly reduces costs associated with performingmechanical decoking operations.

FIG. 2A shows a rear-facing perspective interior view of a mobile waterfiltration system 200 in accordance with one or more embodiments of thepresent invention. In certain embodiments, the system 200 may includefiltration and treatment equipment disposed in a mobile trailer 210 thatfacilitates placing the system 200 on-site and travel from site to site.In other embodiments, the filtration and treatment equipment may bedisposed on a mobile skid (not shown). In still other embodiments, thefiltration and treatment equipment may be disposed on any other type orkind of mobile platform (not shown) capable of travel from site to site.One of ordinary skill in the art, having the benefit of this disclosure,will appreciate that the type or kind of mobile trailer, as well as theconfiguration of equipment disposed therein, may vary based on anapplication or design in accordance with one or more embodiments of thepresent invention.

The mobile trailer 210 may include a wastewater inlet connector 280 thatfacilitates fluid connectivity between the source of coke-ladenwastewater (not shown), such as, for example, a dirty water tank of amobile decoking system (e.g., 105 of FIG. 1) that is input into themobile water filtration system 200. Similarly, the mobile trailer 210may include a filtered water outlet connector 290 that facilitates fluidconnectivity between the output of the system 200 and the clean watertank of the mobile decoking system (e.g., 105 of FIG. 1), or oncedecoking operations are complete, discharge to an on-site drain orstorage. The mobile water filtration system 200 may include an accessdoor 230 to a control room 240 that safely houses equipment, including acontrol system (e.g., 385 of FIG. 7), used to control the operation ofthe system 200, discussed in more detail herein. In the filtration andtreatment area, the system 200 may further include a first pumpingsystem 305 a, a first filtration system (e.g., 310 a, not shown in thisview), and a first tank 325 disposed within the mobile trailer 210. Inbatching embodiments, the system 200 may further include a coagulantpumping system 335 that fluidly communicates coagulant from a coagulanttank 336 to the first tank 325, discussed in more detail herein. Thesystem 200 may further include a flocculant pumping system 340 thatfluidly communicates flocculant (not shown) from a flocculant tank 341to the first tank 325, discussed in more detail herein. In continuousoperation embodiments, the system 200 may not require one or more ofcoagulant pumping system 335, coagulant tank 336, flocculant pumpingsystem 340, and/or flocculant tank 341. The first tank 325 may befluidly connected to an inlet of a second pumping system 305 b.

The system 200 may further include the second pumping system 305 b, asecond filtration system 310 b, and a second tank 365 also disposedwithin the mobile trailer 210. The second tank 365 may be fluidlyconnected to an inlet of a third pumping system 305 c. The system 200may further include the third pumping system 305 c, a third filtrationsystem 310 c, and a fourth filtration system 380 that are disposedwithin the mobile trailer 210. An outlet of the fourth filtration system380 may be fluidly connected to the outlet connector 290. Continuing,FIG. 2B shows a front-facing perspective interior view of a mobile waterfiltration system 200 in accordance with one or more embodiments of thepresent invention. The mobile trailer 210 may include a mobile hitch 220to facilitate transport, a ladder 260 to provide rooftop access to themobile trailer 210, and a plurality of safety rails 270 disposed alongthe rooftop of the mobile trailer 210. Continuing, FIG. 2C shows a topplan interior view of a mobile water filtration system 200 in accordancewith one or more embodiments of the present invention. In this view, thelocation of the control room 240 in the rear of the mobile trailer 210as well as the relative location of the filtration and treatmentequipment is shown. However, one of ordinary skill in the art, havingthe benefit of this disclosure, will appreciate that the orientation,placement, and configuration of equipment may vary based on anapplication or design in accordance with one or more embodiments of thepresent invention.

FIG. 3A shows a top plan exploded view of a mobile water filtrationsystem 200 in accordance with one or more embodiments of the presentinvention. Coke-laden wastewater may be input into the system 200 via awastewater inlet connector 280. A first pumping system 305 a, a firstfiltration system 310 a, and a first tank 325 may be disposed within themobile trailer (e.g., 210, not shown in this view). The wastewater inletconnector 280 may be fluidly connected, via a conduit 302 a, to an inlet(not independently illustrated) of the first pumping system 305 a. Anoutlet (not independently illustrated) of the first pumping system 305 amay be fluidly connected, via a conduit 302 b, to an inlet (notindependently illustrated) of the first filtration system 310 a. Anoutlet (not independently illustrated) of the first filtration system310 a may be fluidly connected, via a conduit 320, to an inlet of thefirst tank 325.

A second pumping system 305 b, a second filtration system 310 b, and asecond tank 365 may also be disposed within the mobile trailer (e.g.,210, not shown in this view). An outlet (not independently illustrated)of the first tank 325 may be fluidly connected, via valves 350 a and 350b (not shown) and a conduit 302 c, to an inlet (not independentlyillustrated) of the second pumping system 305 b. An outlet (notindependently illustrated) of the second pumping system 305 b may befluidly connected, via a conduit 302 d, to an inlet (not independentlyillustrated) of second filtration system 310 b. An outlet (notindependently illustrated) of the second filtration system 310 b may befluidly connected, via a conduit 360, to an inlet (not independentlyillustrated) of the second tank 365.

A third pumping system 305 c, a third filtration system 305 c, and afourth filtration system 380 may also be disposed within the mobiletrailer (e.g., 210, not shown in this view). An outlet (notindependently illustrated) of the second tank 365 may be fluidlyconnected, via valves 350 c and 350 d (not shown) and a conduit 302 e,to an inlet (not independently illustrated) of the third pumping system305 c. An outlet (not independently illustrated) of the third pumpingsystem 305 c may be fluidly connected, via a conduit 302 f, to an inlet(not independently illustrated) of the third filtration system 305 c. Anoutlet (not independently illustrated) of the third filtration system305 c may be fluidly connected, via a conduit 302 g, to an inlet (notindependently illustrated) of the fourth filtration system 380. Anoutlet (not independently illustrated) of the fourth filtration system380 may be fluidly connected, via a conduit 302 h, to the filtered wateroutlet connector 290.

Continuing, FIG. 3B shows a rear-facing perspective exploded view of amobile water filtration system 200 in accordance with one or moreembodiments of the present invention. First tank 325 may include dualported outputs (e.g., 345 a, 345 b of FIG. 3C) that are fluidlyconnected to dual ported inputs of conduit 302 c via valves 350 a and350 b. A single ended output of conduit 302 c may fluidly connect to theinlet (not independently illustrated) of the second pumping system 305b. Continuing, FIG. 3C shows a front-facing perspective exploded view ofa mobile water filtration system 200 in accordance with one or moreembodiments of the present invention. Similar to dual ported outputs 345a and 345 b of first tank 325, second tank 365 may also include dualported outputs 375 a and 375 b that are fluidly connected to dual portedinputs of conduit 302 e via valves 350 c and 350 d. A single endedoutput of conduit 302 e may fluidly connect to the inlet (notindependently illustrated) of the third pumping system 305 c.

FIG. 4A shows a rear-facing perspective view of a first pumping system305 a, first filtration system 310 a, second pumping system 305 b, andsecond filtration system 310 b of a mobile water filtration system 200in accordance with one or more embodiments of the present invention. Inthis view, fluid communication from inlet connector 280 to first pumpingsystem 305 a is more clearly shown. In certain embodiments, firstpumping system 305 a may be, for example, an All-Flo® A300 air-operateddouble-diaphragm pump. Such pumping systems have a fluid inlet (notindependently labeled) on the bottom portion of the pump, an air input(not independently labeled) disposed between the diaphragms (not shown)that receives compressed air, and a fluid outlet (not independentlylabeled) on the top portion of the pump. In such a device, an air-valve(not shown) directs pressurized air behind the diaphragm (not shown) onthe right, causing the diaphragm (not shown) on the right to moveoutward to the right. Since the right diaphragm (not shown) and the leftdiaphragm (not shown) are connected via a connecting rod (not shown),when the right diaphragm (not shown) moves to the right, the leftdiaphragm (not shown) also moves to the right. When the diaphragm (notshown) on the left side moves to the right, in what is referred to as asuction stroke, the left suction ball (not shown) moves upwards to openand the left discharge ball (not shown) moves downward to close. Theseactions under air pressure create suction and draw fluids into the leftside chamber.

The air-valve (not shown) also directs pressurized air behind the leftdiaphragm (not shown), causing the left diaphragm (not shown) to moveoutward to the left. Since both the left diaphragm (not shown) an theright diaphragm (not shown) are connected via the connecting rod (notshown), when the left diaphragm (not shown) moves outward, the leftdischarge ball (not shown) moves upwards to open and the left suctionball (not shown) moves downward to close. This causes fluids to leavethe outlet of the pump. Simultaneously, the right diaphragm (not shown)moves inward to the left, which causes the right suction ball (notshown) to open and the right discharge ball (not shown) to close, whichin turn creates suction, drawing fluids into the right chamber. Thisprocess of alternating right suction and left discharge, as well as leftsuction and right discharge, creates a pumping action that draws in andconveys fluids in a manner that is controllable by the application ofcompressed air to the air-valve (not shown). The control system (e.g.,385 of FIG. 7) may be calibrated based on the type or kind of pumpingsystem used such that the control system can control the operation ofthe pumping system in its full range of operation with certainty.

In certain embodiments, second pumping system 305 b and third pumpingsystem (e.g., 305 c) may be the same type or kind of pumping system asthat of 305 a and may operate in the same manner. Notwithstanding theabove, one of ordinary skill in the art, having the benefit of thisdisclosure, will appreciate that the above-noted pumping system ismerely exemplary and other types or kinds of pumping systems may be usedin accordance with one or more embodiments of the present invention. Inaddition, one of ordinary skill in the art will also appreciate that thefirst pumping system 305 a, second pumping system 305 b, and thirdpumping system 305 c may not be the same and may vary in accordance withone or more embodiments of the present invention. Fluids pumped by firstpumping system 305 a are directed to an inlet (not independentlylabeled) of the first filtration system 310 a. In certain embodiments,first filtration system 310 a may be, for example, a Rosedale Products®Model 82 quad capacity filtration system. Such filtration systems havean inlet (not independently labeled) on a top side and an outlet (notshown) disposed on a bottom side. Fluids are conveyed from inlet,through a plurality of filters or baskets, to the outlet. While theembodiment depicted includes a quad capacity filtration system, one ofordinary skill in the art will recognize that the capacity required mayvary based on the flow rates of fluids expected to flow therethrough andan appropriate filtration system may be used in accordance with one ormore embodiments of the present invention. In certain embodiments,second filtration system 310 b and third filtration system (e.g., 310 c)may be the same type or kind of filtration system as that of 310 a andmay operate in the same manner. Notwithstanding the above, one ofordinary skill in the art, having the benefit of this disclosure, willappreciate that the above-noted filtration system is merely exemplaryand other types or kinds of filtration systems may be used in accordancewith one or more embodiments of the present invention. In addition, oneof ordinary skill in the art will also appreciate that the firstfiltration system 310 a, second filtration system 310 b, and thirdfiltration system 310 c may not be the same and may vary in accordancewith one or more embodiments of the present invention.

In one or more embodiments of the present invention, a plurality ofcascaded filtration systems may be used that filter increasingly fineparticles out of the wastewater as it proceeds through the system 200.In certain embodiments, the first filtration system 310 a may use aplurality of filters (not shown) that filter particles having a size ina range between 750 microns and 80 microns. The second filtration system310 b may use a plurality of filters (not shown) that filter particleshaving a size in a range between 300 microns and 60 microns. The thirdfiltration system (e.g., 310 c) may use a plurality of filters (notshown) that filter particles having a size in a range between 150microns and 40 microns. The fourth filtration system (e.g., 380) may usea plurality of filters (not shown) that filter particles having a sizesmaller than 150 microns or 40 microns. One of ordinary skill in the artwill appreciate that the types or kinds of filters used at each stage,as well as the range of particulate matter that they are capable offiltering out, may vary based on an application or design in accordancewith one or more embodiments of the present invention. In addition, oneof ordinary skill in the art will appreciate that the types or kinds offilters, as well as the range of particulate matter that they arecapable of filtering out, may vary based on the nature of the wastewaterand the particulate matter therein, that may vary from application toapplication, in accordance with one or more embodiments of the presentinvention.

Continuing, FIG. 4B shows a top plan view of a first pumping system 305a, first filtration system 310 a, second pumping system 305 b, andsecond filtration system 310 b of a mobile water filtration system 200in accordance with one or more embodiments of the present invention. Inthe example depicted, each of pumping systems 305 a, 305 b, and 305 c(not shown) may include a right-side diaphragm housing 307 a and a leftside diaphragm housing 307 b that house their respective right side andleft side diaphragms (not shown). Similarly, each of filtration systems310 a, 310 b, 310 c (not shown), and 380 (not shown) may include aplurality of filter/basket housings 311 that house their respectivefilters or baskets (not shown). Continuing, FIG. 4C shows a front-facingperspective view of a third pumping system 305 c, third filtrationsystem 310 c, and fourth filtration system 380 of a mobile waterfiltration system 200 in accordance with one or more embodiments of thepresent invention. As noted above, third pumping system 305 c may use aplurality of filters (not shown) that filter particles having a size ina range between 150 microns and 40 microns. The fourth filtration system380 may use a plurality of filters (not shown) that filter particleshaving a size smaller than 150 microns or 40 microns. Continuing, FIG.4D shows a top plan view of a third pumping system 305 c, thirdfiltration system 310 c, and fourth filtration system 380 of a mobilewater filtration system 200 in accordance with one or more embodimentsof the present invention. Since the fourth filtration system 380 isfiltering particulate matter that is exceptionally small, thereby havinga high flow rate therethrough, a filtration system with fewerfilter/basket housings 311 may be used. In this instance, the fourthfiltration system 380 may be a dual, rather than a quad, filter/baskettype filtration system. However, one of ordinary skill in the art willappreciate that the selection of a type or kind of filtration system mayvary based on the application or design in accordance with one or moreembodiments of the present invention. If different flow rates orwastewater with different profiles of particulate contamination areexpected, simulation or experimentation may be used to ensure the properselection of the filtration systems suitable for a particularapplication.

FIG. 5 shows a block diagram of a mobile water filtration system 200 inaccordance with one or more embodiments of the present invention. Thesystem 200 may include a mobile trailer (e.g., 200 of FIG. 2) thatincludes an inlet connector 280 and an outlet connector 290.

A first pumping system 305 a, a first filtration system 310 a, and afirst tank 325 may be disposed in the mobile trailer (e.g., 200 of FIG.2). The inlet connector 280 may be fluidly connected to an inlet of thefirst pumping system 305 a, an outlet of the first pumping system 305 amay be fluidly connected to an inlet of the first filtration system 310a, and an outlet of the first filtration system 310 a may be fluidlyconnected to an inlet of the first tank 325.

A second pumping system 305 b, a second filtration system 310 b, and asecond tank 365 may be disposed in the mobile trailer (e.g., 200 of FIG.2). An outlet of the first tank 325 may be fluidly connected to an inletof the second pumping system 305 b, an outlet of the second pumpingsystem 305 b may be fluidly connected to an inlet of the secondfiltration system 310 b, and an outlet of the second filtration system310 b may be fluidly connected to an inlet of the second tank 365.

A third pumping system 305 c, a third filtration system 310 c, and afourth filtration system 380 may be disposed in the mobile trailer(e.g., 200 of FIG. 2). An outlet of the second tank may be fluidlyconnected to an inlet of the third pumping system 305 c, an outlet ofthe third pumping system 305 c may be fluidly connected to an inlet ofthe third filtration system 310 c, an outlet of the third filtrationsystem 310 c may be fluidly connected to an inlet of the fourthfiltration system 380, and an outlet of the fourth filtration system 380may be fluidly connected to the outlet connector 290. A control system385 may control a pump speed of the first pumping system 305 a, thesecond pumping system 305 b, and a third pumping system 305 c bycontrolling the application of air pressure to the air valves (notshown) of each pumping system.

A coagulant tank 336 may be fluidly connected to an inlet of a coagulantpumping system 335 and an outlet of the coagulant pumping system 335 maybe fluidly connected to the first tank 325. The control system 385 maycontrol the pump speed of the coagulant pumping system 335 to controlthe fluid communication of coagulant (not shown) from the coagulant tank336 to the first tank 325. In certain embodiments, the coagulant may bealuminum sulfate, commonly referred to as alum. In other embodiments,the coagulant may be aluminum chlorohydrate. In still other embodiments,the coagulant may be polyaluminum chloride, ferric sulfate, or ferricchloride. One of ordinary skill in the art will appreciate that thecoagulant may vary based on the type of hydrocarbons present inaccordance with one or more embodiments of the present invention.Similarly, a flocculant tank 341 may be fluidly connected to an inlet ofa flocculant pumping system 340 and an outlet of the flocculant pumpingsystem 340 may be fluidly connected to the first tank 325. The controlsystem 385 may control the pump speed of the flocculant pumping system340 to control the fluid communication of flocculant (not shown) fromthe flocculant tank 341 to the first tank 325. In certain embodiments,the flocculant may an anionic polyacrylamide flocculant. In otherembodiments, the flocculant may be a cationic polyacrylamide flocculant.In still other embodiments, the flocculant may be a cationicwater-soluble polymer in emulsion. In still other embodiments, theflocculant may be emulsion based on cationic polyacrylamide. In stillother embodiments, the flocculant may be commercially availableflocculant under trade names AR-288, FBS-7802, FBS-7602, FBS-5804, orFBS-5604. One of ordinary skill in the art will appreciate that theflocculant may vary based on the type of hydrocarbons present inaccordance with one or more embodiments of the present invention.

In one or more embodiments of the present invention, a plurality ofvalves may be used as part of control and automation of the system 200.For example, one or more valves (e.g., 350 a, 350 b) may control fluidcommunication between the first tank 325 and the second pump system 305b. Similarly, one or more valves (e.g., 350 c, 350 d) may control fluidcommunication between the second tank 365 and the third pump system 305c. In addition, one or more valves (e.g., 350 e) may control fluidcommunication between the fourth filtration system 380 and the outletconnector 290. Each valve (e.g., 350) may be electronically controllableby the control system 385, as discussed in more detail herein. The firstfiltration system 310 a may include one or more filters that filterparticles having a size in a range between 750 microns and 80 microns.The second filtration system 310 b may include one or more filters thatfilter particles having a size in a range between 300 microns and 60microns. The third filtration system 310 c may include one or morefilters that filter particles having a size in a range between 150microns and 40 microns. The fourth filtration system 380 may include oneor more filters that filter particles having a size smaller than 150microns or 40 microns. One of ordinary skill in the art will recognizethat the cascaded filter sizes may vary to enhance fluid flow ratethrough the system and prevent bottlenecking. The inlet connector 280may receive wastewater from a dirty water tank of a mobile decokingsystem (e.g., 105 of FIG. 1) or frac tank and the outlet connector 290may provide filtered water to a clean water tank (not shown) of themobile decoking system (e.g., 105 of FIG. 1) or discharge the filteredwater to an on-site drain or storage.

In one or more embodiments of the present invention, a plurality ofcontrols may be used as part of control and automation of the system200. For example, a first air regulator, AR1, may be used to regulatethe provision of pressurized air, and thereby control the speed of, thefirst pumping system 305 a, a second air regulator, AR2, may be used toregulate the provision of pressurized air, and thereby control the speedof, the second pumping system 305 b, and finally, a third air regulator,AR3, may be used to regulate the provision of pressurized air, andthereby control the speed of, the third pumping system 305 c. Thecontrol system 385 may control the air regulators AR1, AR2, and AR3, andthereby control the pump speeds of the first, second, and third pumpingsystems 305 a, 305 b, and 305 c.

In one or more embodiments of the present invention, a plurality ofsensors may be used as part of control and automation of the system 200.For example, a temperature sensor, TT1, may measure temperature offluids prior to the first filtration system 310 a, a first flow meter,FT1, may measure fluid flow into the first filtration system 310 a, asecond flow meter, FT2, may measure fluid flow into the secondfiltration system 310 b, a third flow meter, FT3, may measure fluid flowinto the third filtration system 310 c, and a fourth flow meter, FT4,may measure fluid flow into the fourth filtration system 380. Thecontrol system 385 may monitor the temperature and flow rates of fluidsas part of the control and automation of the system 200.

In one or more embodiments of the present invention, a plurality oflevel gauges may be used as part of control and automation of the system200. For example, a first tank level gauge, TG1, may be used to measurethe tank volume of the first tank 325, a second tank level gauge, TG2,may be used to measure the tank volume of the second tank 365, one ormore coagulant level gauges, CG1 and CG2, may be used to measure thetank volumes of one or more coagulant tanks 336, and a flocculant levelgauge, FG1, may be used to measure the tank volume of a flocculant tank341. The control system 385 may monitor the tank volumes as part of thecontrol and automation of the system 200.

In one or more embodiments of the present invention, a plurality ofpressure sensors or transducers may be used as part of control andautomation of the system 200. For example, a pressure sensor, PT1, maybe disposed on the inlet side of the first filtration system 310 a and apressure sensor, PT2, may be disposed on the outlet side of the firstfiltration system 310 a, a pressure sensor PT3, may be disposed on theinlet side of the second filtration system 310 b and a pressure sensor,PT4, may be disposed on the outlet side of the first filtration system310 b, a pressure sensor, PT5, may be disposed on the inlet side ofthird filtration system 310 c and a pressure sensor, PT6, may bedisposed on the outlet side of the third filtration system 310 c, and apressure sensor, PT7, may be disposed on the inlet side of the fourthfiltration system 380 and a pressure sensor, PT8, may be disposed on theoutlet side of the fourth filtration system 380. The control system 385may monitor the pressure readings from the pressure sensors and use thereadings to determine whether the filters require replacement, asdiscussed in more detail herein.

FIG. 6A shows a batch method of mobile water filtration in accordancewith one or more embodiments of the present invention. A control system(e.g., 385) may monitor 605 a first tank volume, TG1. If the fluidvolume, TG1, of the first tank (e.g., 325) falls below or is less than apredetermined volume, Vol_(StartFirst), (e.g., TG1<≈500 gallons), thecontrol system (e.g., 385) may start 610 the first pumping system (e.g.,305 a) to fluidly communicate fluids from an inlet connector (e.g., 280)to the first pumping system (e.g., 305 a), a first filtration system(e.g., 310 a), and the first tank (e.g., 325), and stop 615 the secondpumping system (e.g., 305 b), thereby allowing the first tank (e.g.,325) to start filling. One of ordinary skill in the art will recognizethat the predetermined volume, Vol_(StartFirst), may be used as a metricof when to start filling the first tank (e.g., 325) and may vary basedon the tank sizes, anticipated flow rates, pump capacity, and filtrationcapacity in accordance with one or more embodiments of the presentinvention. In certain embodiments, the predetermined volume,Vol_(StartFirst), may be in a range between 0 and 500 gallons. In otherembodiments, the predetermined volume, Vol_(StartFirst), may be in arange between 0 and 250 gallons. In still other embodiments, thepredetermined volume, Vol_(StartFirst), may be in a range between 250and 500 gallons.

If the fluid volume, TG1, of the first tank (e.g., 325) reaches apredetermined volume, Vol_(StartCoagutant), (e.g., TG1≈500 gallons), thecontrol system (e.g., 385) may start 620 the coagulant pumping system(e.g., 335) to fluidly communicate a predetermined volume of coagulantfrom the coagulant tank (e.g., 336) into the first tank (e.g., 325) andthen stop 625 the coagulant pumping system (e.g., 335) after thepredetermined volume, Vol_(Coagulant), has been pumped into the firsttank (e.g., 325). In certain embodiments, the predetermined volume,Vol_(StartCoagulant), may be in a range between 500 and 1000 gallons. Inother embodiments, the predetermined volume, Vol_(StartCoagulant), maybe in a range between 500 and 750 gallons. In still other embodiments,the predetermined volume, Vol_(StartCoagulant), may be in a rangebetween 750 and 1000 gallons. One of ordinary skill in the art willrecognize that the predetermined volume may vary based on the tank sizeand the chemical composition of the coagulant in accordance with one ormore embodiments of the present invention. In certain embodiments, thepredetermined volume of coagulant, Vol_(Coagulant), may be in a rangebetween 1 and 10 gallons for every 2000 gallons in the first tank (e.g.,325). In other embodiments, the predetermined volume of coagulant,Vol_(Coagulant), may be in a range between 1 and 3 gallons for every2000 gallons in the first tank (e.g., 325). In still embodiments, thepredetermined volume of coagulant, Vol_(Coagulant), may be in a rangebetween 3 and 6 gallons for every 2000 gallons in the first tank (e.g.,325). One of ordinary skill in the art will recognize that thepredetermined volume of coagulant may vary based on the type ofhydrocarbons present, the tank size, and the chemical composition of thecoagulant in accordance with one or more embodiments of the presentinvention. Since the system 200 may be dynamic, the control system(e.g., 385) may dynamically and intelligently adjust the predeterminedvolume of coagulant. One of ordinary skill in the art will recognizethat the second predetermined volume may be used as a metric of when tostart application of coagulant and may vary based on the tank sizes,anticipated flow rates, pump capacity, and filtration capacity inaccordance with one or more embodiments of the present invention.

If the fluid volume, TG1, of the first tank (e.g., 325) reaches apredetermined volume, Vol_(StartFlocculant), (e.g., TG1≈1000 gallons),the control system (e.g., 385) may start 630 the flocculant pumpingsystem (e.g., 340) to fluidly communicate a predetermined volume offlocculant, Vol_(Flocculant), from the flocculant tank (e.g., 341) intothe first tank (e.g., 325). In certain embodiments, the predeterminedvolume, Vol_(StartFlocculant), may be in a range between 1000 and 1500gallons. In other embodiments, the predetermined volume,Vol_(StartFlocculant), may be in a range between 1000 and 1250 gallons.In still other embodiments, the predetermined volume,Vol_(StartFlocculant), may be in a range between 1250 and 1500 gallons.One of ordinary skill in the art will recognize that the predeterminedvolume may vary based on the tank size and the chemical composition ofthe flocculant in accordance with one or more embodiments of the presentinvention. In certain embodiments, the predetermined volume offlocculant, Vol_(Flocculant), may be in a range between 0.1 and 10gallons for every 2000 gallons in the first tank (e.g., 325). In otherembodiments, the predetermined volume of flocculant, Vol_(Flocculant),may be in a range between 0.1 and 2 gallons for every 2000 gallons inthe first tank (e.g., 325). In still embodiments, the predeterminedvolume of flocculant, Vol_(Flocculant), may be in a range between 2 and10 gallons for every 2000 gallons in the first tank (e.g., 325). One ofordinary skill in the art will recognize that the predetermined volumeof flocculant may vary based on the type of hydrocarbons present, thetank size, and the chemical composition of the flocculant in accordancewith one or more embodiments of the present invention. Since the system200 may be dynamic, the control system (e.g., 385) may dynamically andintelligently adjust the predetermined volume of flocculant. One ofordinary skill in the art will recognize that the third predeterminedvolume may be used as a metric of when to start application offlocculant and may vary based on the tank sizes, anticipated flow rates,pump capacity, and filtration capacity in accordance with one or moreembodiments of the present invention. After injection of the flocculant,the control system (e.g., 385) may pause for a predetermined amount oftime to allow the first tank (e.g., 325) to settle 640 and then start645 the second pumping system (e.g., 305 b) to fluidly communicatefluids from the first tank (e.g., 325) to a second filtration system(e.g., 310 b) and the second tank (e.g., 625). In certain embodiments,the predetermined amount of time to allow the first tank (e.g., 325) tosettle may be in a range between 30 seconds and 5 minutes. One ofordinary skill in the art will recognize that the predetermined amountof time to settle may vary based on the type of hydrocarbons present,the tank size, and the chemical composition of the coagulant andflocculant used in accordance with one or more embodiments of thepresent invention.

Continuing, FIG. 6B shows a method of mobile water filtration inaccordance with one or more embodiments of the present invention. Acontrol system (e.g., 385) may monitor 650 a second tank volume, TG2. Ifthe fluid volume, TG2, of the second tank (e.g., 625) reaches apredetermined volume, Vol_(StartThird), (e.g., TG2≈1500 gallons), thecontrol system (e.g., 385) may start 655 a third pumping system (e.g.,305 c) to fluidly communicate fluids from the second tank (e.g., 625) toa third filtration system (e.g., 310 c), a fourth filtration system(e.g., 380), and an outlet connector (e.g., 290) and stop 660 the thirdpumping system (e.g., 305 c) if the fluid volume falls below apredetermined volume, Vol_(StopThird). In certain embodiments, thepredetermined volume, Vol_(StartThird), may be in a range between 1000and 1500 gallons. In other embodiments, the predetermined volume,Vol_(StartThird), may be in a range between 1000 and 1250 gallons. Instill embodiments, the predetermined volume, Vol_(StartThird), may be ina range between 1250 and 1500 gallons. One of ordinary skill in the artwill recognize that the predetermined volume, Vol_(StartThird), may varybased on the tank size in accordance with one or more embodiments of thepresent invention. In certain embodiments, the predetermined volume,Vol_(StopThird), may be in a range between 500 and 0 gallons. In otherembodiments, the predetermined volume, VOl_(StopThird), may be in arange between 500 and 250 gallons. In still embodiments, thepredetermined volume, Vol_(StopThird), may be in a range between 250 and0 gallons. One of ordinary skill in the art will recognize that thepredetermined volume, Vol_(StopThird), may vary based on the tank sizein accordance with one or more embodiments of the present invention. Ifthe fluid volume, TG2, of the second tank (e.g., 625) reaches apredetermined volume, Vol_(StopSecond), (e.g., TG2≈2000 gallons), thecontrol system (e.g., 385) may stop 665 the second pumping system (e.g.,305 b) to prevent further fluids from being directed to the second tank(e.g., 625). In certain embodiments, the predetermined volume,VOl_(StopSecond), may be in a range between 1500 and 2000 gallons. Inother embodiments, the predetermined volume, Vol_(StopSecond), may be ina range between 1500 and 1750 gallons. In still embodiments, thepredetermined volume, Vol_(StopSecond), may be in a range between 1750and 2000 gallons. One of ordinary skill in the art will recognize thatthe predetermined volume, Vol_(StopSecond), may vary based on the tanksize in accordance with one or more embodiments of the presentinvention.

FIG. 6C shows a method of mobile water filtration in accordance with oneor more embodiments of the present invention. The control system (e.g.,385) may monitor 670 the pressure differential (PT1-PT2) across thefirst filtration system (e.g., 310 a). If the pressure differential,PD1, exceeds a predetermined threshold in pounds per square inch (“psi”)(e.g., PT1-PT2>≈15 psi), the control system (e.g., 385) may stop 675 thefirst pumping system (e.g., 305 a) to enable an operator to service thefilters of the first filtration system (e.g., 310 a) and then restartthe first pumping system (e.g., 305 a) after the filters have beencleaned or replaced. In certain embodiments, the pressure differential,PD1, may be in a range between 10 and 50 psi. In other embodiments, thepressure differential, PD1, may be in a range between 10 and 25 psi. Instill other embodiments, the pressure differential, PD1, may be in arange between 25 and 50 psi. One of ordinary skill in the art willrecognize that the pressure differential, PD1, may vary based on thetype or kind of filtration system used. The control system (e.g., 385)may monitor 680 the pressure differential (PT3-PT4) across the secondfiltration system (e.g., 310 b). If the pressure differential, PD2,exceeds a predetermined threshold (e.g., PT3-PT4>≈15 psi), the controlsystem (e.g., 385) may stop 685 the second pumping system (e.g., 305 b)to enable an operator to service the filters of the second filtrationsystem (e.g., 310 b) and then restart the second pumping system (e.g.,305 b) after the filters have been cleaned or replaced. In certainembodiments, the pressure differential, PD2, may be in a range between10 and 50 psi. In other embodiments, the pressure differential, PD2, maybe in a range between 10 and 25 psi. In still other embodiments, thepressure differential, PD2, may be in a range between 25 and 50 psi. Oneof ordinary skill in the art will recognize that the pressuredifferential, PD2, may vary based on the type or kind of filtrationsystem used.

The control system (e.g., 385) may monitor 690 the pressure differential(PT4-PT5) across the third filtration system (e.g., 310 c). If thepressure differential, PD3, exceeds a predetermined threshold (e.g.,PT4-PT5>≈15 psi), the control system (e.g., 385) may stop 695 the thirdpumping system (e.g., 305 c) to enable an operator to service thefilters of the third filtration system (e.g., 310 c) and then restartthe third pumping system (e.g., 305 c) after the filters have beencleaned or replaced. In certain embodiments, the pressure differential,PD3, may be in a range between 10 and 50 psi. In other embodiments, thepressure differential, PD3, may be in a range between 10 and 25 psi. Instill other embodiments, the pressure differential, PD3, may be in arange between 25 and 50 psi. One of ordinary skill in the art willrecognize that the pressure differential, PD3, may vary based on thetype or kind of filtration system used. The control system (e.g., 385)may monitor 697 the pressure differential (PT6-PT7) across the fourthfiltration system (e.g., 380). If the pressure differential, PD4,exceeds a predetermined threshold (e.g., PT6-PT7>≈15 psi), the controlsystem (e.g., 385) may stop 699 the third pumping system (e.g., 305 c)to enable an operator to service the filters of the fourth filtrationsystem (e.g., 380) and then restart the third pumping system (e.g., 305c) after the filters have been cleaned or replaced. In certainembodiments, the pressure differential, PD4, may be in a range between10 and 50 psi. In other embodiments, the pressure differential, PD4, maybe in a range between 10 and 25 psi. In still other embodiments, thepressure differential, PD4, may be in a range between 25 and 50 psi. Oneof ordinary skill in the art will recognize that the pressuredifferential, PD4, may vary based on the type or kind of filtrationsystem used.

In one or more embodiments of the present invention, depending on thetype of hydrocarbons present, the above-noted method may be modified forcontinuous operation rather than batching as shown and described withrespect to FIG. 6A. In a continuous application, coagulant and/orflocculant, and associated equipment thereof, may not be required or maybe manually shutoff. Similar to the above, a control system (e.g., 385)may monitor 605 a first tank volume, TG1. If the fluid volume, TG1, ofthe first tank (e.g., 325) falls below or is less than a predeterminedvolume, Vol_(StartFirst), (e.g., TG1<≈500 gallons), the control system(e.g., 385) may start 610 the first pumping system (e.g., 305 a) tofluidly communicate fluids from an inlet connector (e.g., 280) to thefirst pumping system (e.g., 305 a), a first filtration system (e.g., 310a), and the first tank (e.g., 325), and stop 615 the second pumpingsystem (e.g., 305 b), thereby allowing the first tank (e.g., 325) tostart filling. One of ordinary skill in the art will recognize that thepredetermined volume, Vol_(StartFirst), may be used as a metric of whento start filling the first tank (e.g., 325) and may vary based on thetank sizes, anticipated flow rates, pump capacity, and filtrationcapacity in accordance with one or more embodiments of the presentinvention. In certain embodiments, the predetermined volume,Vol_(StartFirst), may be in a range between 0 and 500 gallons. In otherembodiments, the predetermined volume, Vol_(StartFirst), may be in arange between 0 and 250 gallons. In still other embodiments, thepredetermined volume, Vol_(StartFirst), may be in a range between 250and 500 gallons.

The control system (e.g., 385) may monitor 650 a second tank volume,TG2. If the fluid volume, TG2, of the second tank (e.g., 625) reaches apredetermined volume, Vol_(StartThird), (e.g., TG2≈1500 gallons), thecontrol system (e.g., 385) may start 655 a third pumping system (e.g.,305 c) to fluidly communicate fluids from the second tank (e.g., 625) toa third filtration system (e.g., 310 c), a fourth filtration system(e.g., 380), and an outlet connector (e.g., 290) and stop 660 the thirdpumping system (e.g., 305 c) if the fluid volume falls below apredetermined volume, Vol_(StopThird). In certain embodiments, thepredetermined volume, Vol_(StartThird), may be in a range between 1000and 1500 gallons. In other embodiments, the predetermined volume,Vol_(StartThird), may be in a range between 1000 and 1250 gallons. Instill embodiments, the predetermined volume, Vol_(StartThird), may be ina range between 1250 and 1500 gallons. One of ordinary skill in the artwill recognize that the predetermined volume, Vol_(StartThird), may varybased on the tank size in accordance with one or more embodiments of thepresent invention. In certain embodiments, the predetermined volume,Vol_(StopThird), may be in a range between 500 and 0 gallons. In otherembodiments, the predetermined volume, Vol_(StopThird), may be in arange between 500 and 250 gallons. In still embodiments, thepredetermined volume, Vol_(StopThird), may be in a range between 250 and0 gallons. One of ordinary skill in the art will recognize that thepredetermined volume, Vol_(StopThird), may vary based on the tank sizein accordance with one or more embodiments of the present invention. Ifthe fluid volume, TG2, of the second tank (e.g., 625) reaches apredetermined volume, Vol_(StopSecond), (e.g., TG2≈2000 gallons), thecontrol system (e.g., 385) may stop 665 the second pumping system (e.g.,305 b) to prevent further fluids from being directed to the second tank(e.g., 625). In certain embodiments, the predetermined volume,Vol_(StopSecond), may be in a range between 1500 and 2000 gallons. Inother embodiments, the predetermined volume, Vol_(StopSecond), may be ina range between 1500 and 1750 gallons. In still embodiments, thepredetermined volume, Vol_(StopSecond), may be in a range between 1750and 2000 gallons. One of ordinary skill in the art will recognize thatthe predetermined volume, Vol_(StopSecond), may vary based on the tanksize in accordance with one or more embodiments of the presentinvention.

The control system (e.g., 385) may monitor 670 the pressure differential(PT1-PT2) across the first filtration system (e.g., 310 a). If thepressure differential, PD1, exceeds a predetermined threshold in poundsper square inch (“psi”) (e.g., PT1-PT2>≈15 psi), the control system(e.g., 385) may stop 675 the first pumping system (e.g., 305 a) toenable an operator to service the filters of the first filtration system(e.g., 310 a) and then restart the first pumping system (e.g., 305 a)after the filters have been cleaned or replaced. In certain embodiments,the pressure differential, PD1, may be in a range between 10 and 50 psi.In other embodiments, the pressure differential, PD1, may be in a rangebetween 10 and 25 psi. In still other embodiments, the pressuredifferential, PD1, may be in a range between 25 and 50 psi. One ofordinary skill in the art will recognize that the pressure differential,PD1, may vary based on the type or kind of filtration system used. Thecontrol system (e.g., 385) may monitor 680 the pressure differential(PT3-PT4) across the second filtration system (e.g., 310 b). If thepressure differential, PD2, exceeds a predetermined threshold (e.g.,PT3-PT4>≈15 psi), the control system (e.g., 385) may stop 685 the secondpumping system (e.g., 305 b) to enable an operator to service thefilters of the second filtration system (e.g., 310 b) and then restartthe second pumping system (e.g., 305 b) after the filters have beencleaned or replaced. In certain embodiments, the pressure differential,PD2, may be in a range between 10 and 50 psi. In other embodiments, thepressure differential, PD2, may be in a range between 10 and 25 psi. Instill other embodiments, the pressure differential, PD2, may be in arange between 25 and 50 psi. One of ordinary skill in the art willrecognize that the pressure differential, PD2, may vary based on thetype or kind of filtration system used.

The control system (e.g., 385) may monitor 690 the pressure differential(PT4-PT5) across the third filtration system (e.g., 310 c). If thepressure differential, PD3, exceeds a predetermined threshold (e.g.,PT4-PT5>≈15 psi), the control system (e.g., 385) may stop 695 the thirdpumping system (e.g., 305 c) to enable an operator to service thefilters of the third filtration system (e.g., 310 c) and then restartthe third pumping system (e.g., 305 c) after the filters have beencleaned or replaced. In certain embodiments, the pressure differential,PD3, may be in a range between 10 and 50 psi. In other embodiments, thepressure differential, PD3, may be in a range between 10 and 25 psi. Instill other embodiments, the pressure differential, PD3, may be in arange between 25 and 50 psi. One of ordinary skill in the art willrecognize that the pressure differential, PD3, may vary based on thetype or kind of filtration system used. The control system (e.g., 385)may monitor 697 the pressure differential (PT6-PT7) across the fourthfiltration system (e.g., 380). If the pressure differential, PD4,exceeds a predetermined threshold (e.g., PT6-PT7>≈15 psi), the controlsystem (e.g., 385) may stop 699 the third pumping system (e.g., 305 c)to enable an operator to service the filters of the fourth filtrationsystem (e.g., 380) and then restart the third pumping system (e.g., 305c) after the filters have been cleaned or replaced. In certainembodiments, the pressure differential, PD4, may be in a range between10 and 50 psi. In other embodiments, the pressure differential, PD4, maybe in a range between 10 and 25 psi. In still other embodiments, thepressure differential, PD4, may be in a range between 25 and 50 psi. Oneof ordinary skill in the art will recognize that the pressuredifferential, PD4, may vary based on the type or kind of filtrationsystem used.

FIG. 7 shows a programmable logic controller (“PLC”) based controlsystem 385 of a mobile water filtration system 200 in accordance withone or more embodiments of the present invention. Control system 385 maybe include one or more processing units 710 disposed on one or moreprinted circuit boards (not shown). Each of the one or more processingunits 710 may be a single-core processor (not independently illustrated)or a multi-core processor (not independently illustrated) capable ofeither executing logical functions or executing software instructions.Multi-core processing units typically include a plurality of processorcores (not shown) disposed on the same physical die (not shown) or aplurality of processor cores (not shown) disposed on multiple die (notshown) that are collectively disposed within the same mechanical package(not shown). Control system 385 may include a power supply 720, systemmemory 730, one or more optional human-computer interfaces (“HCI”) 740,and optionally a display 750. The one or more human-computer interfacesmay include an on/off switch (not shown) for the system 200.

Control system 385 may include an input interface 760 that facilitatesinputs from a variety of sources including, but not limited to,regulators, meters, gauges, sensors, and transducers such as, forexample, data provided by temperature sensor TT1, flow meters FT1, FT2,FT3, and FT4, pressure transducers PT1, PT2, PT3, PT4, PT5, PT6, PT7,and PT8, tank volumes TG1 and TG2, coagulant tank volumes CG1 and CG2,flocculant tank volumes FG1, and the state of valves V1, V2, V3, V4, andV5. The control system 385 may also include an output interface 770 thatfacilitates outputs used as part of control and automation of the system200. For example, control system 385 may, through the output interface770, independently control the state (opened or closed) of valves V1,V2, V3, V4, and V5. In addition, control system 385 may control the pumpspeeds of the first pumping system (e.g., 305 a), the second pumpingsystem (e.g., 305 b), and the third pumping system (e.g., 305 c), bycontrolling the amount of air pressure that the air regulators AR1, AR2,and AR3 provide to the first pumping system (e.g., 305 a), the secondpumping system (e.g., 305 b), and the third pumping system (e.g., 305 c)respectively. The control system 385 may control the pump speeds of thecoagulant pumping system 335 and the flocculant pumping system 340. Inaddition, control system 385 may, through either the output interface770 or the HCI 740 or optional display 750, provide a signal to anoperator that a pressure differential has exceeded a predeterminedthreshold and that a particular filtration system (e.g., 310 a, 310 b,310 c, and 380) requires filter service. One of ordinary skill in theart will appreciate that the control system 385 may be programmed toimplement one or more of the methods disclosed herein, thereby enablingautomation of the mobile water filtration system 200.

FIG. 8 shows an exemplary application of a mobile water filtrationsystem 200 disposed on-site supporting decoking operations of a firedheater 100 in accordance with one or more embodiments of the presentinvention. In the example depicted, a mobile decoking system 105, suchas that commercially offered by Cokebusters® USA Inc., of Houston, Tex.,may be disposed on-site, one or more pigs (not shown) may be deployedwithin, and the decoking system may be connected to, the radiant tubesand convection tubes of the tubular coils 130 and 150. Mobile waterfiltration system 200 may be brought onto the site and at least twoconnections are required, connecting the inlet connector of the system200 to wastewater, or dirty water, tank of the decoking system 105 andconnecting the outlet connector of system 200 to the clean water tank ofthe decoking system 105. As the decoking system 105 performs themechanical decoking operation and fills its wastewater tank, the mobilewater filtration system 200 may automatically draw the water out of thetank, filter and treat the coke-laden water, and after processingprovide filtered water back to clean water tank of the decoking system105 for reuse or, if the decoking operation is complete, discharge to adrain or storage.

In one or more embodiments of the present invention, a mobile waterfiltration system for on-site decoking operations may include a mobiletrailer comprising an inlet connector and an outlet connector. An outletof a dirty water tank of, for example, a mobile decoking system, mayfluidly connect to the inlet connector. The outlet connector may fluidlyconnect to a clean water tank of, for example, the mobile decokingsystem or an on-site drain. The system may further include a firstpumping system, a first filtration system, and a first tank disposed inthe mobile trailer, where the inlet connector is fluidly connected to aninlet of the first pumping system, an outlet of the first pumping systemis fluidly connected to an inlet of the first filtration system, and anoutlet of the first filtration system is fluidly connected to an inletof the first tank. The system may further include a second pumpingsystem, a second filtration system, and a second tank disposed in themobile trailer, where an outlet of the first tank is fluidly connectedto an inlet of the second pumping system, an outlet of the secondpumping system is fluidly connected to an inlet of the second filtrationsystem, and an outlet of the second filtration system is fluidlyconnected to an inlet of the second tank. The system may further includea third pumping system, a third filtration system, and a fourthfiltration system disposed in the mobile trailer, where an outlet of thesecond tank is fluidly connected to an inlet of the third pumpingsystem, an outlet of the third pumping system is fluidly connected to aninlet of the third filtration system, an outlet of the third filtrationsystem is fluidly connected to an inlet of the fourth filtration system,and an outlet of the fourth filtration system is fluidly connected tothe outlet connector. A control system that controls a pump speed of thefirst pumping system, the second pumping system, and the third pumpingsystem.

In one or more embodiments of the present invention, the system mayfurther include a coagulant tank fluidly connected to a coagulantpumping system, where the control system controls a pump speed of thecoagulant pumping system that fluidly communicates coagulant from thecoagulant tank to the first tank. The system may further include aflocculant tank fluidly connected to a flocculant pumping system,wherein the control system controls a pump speed of the flocculantpumping system that fluidly communicates flocculant from the flocculanttank to the first tank. In one or more embodiments of the presentinvention, the system may further include one or more valves thatcontrol fluid communication between the first tank and the second pumpsystem, one or more valves that control fluid communication between thesecond tank and the third pump system, and a valve that controls fluidcommunication between the fourth filtration system and the water outletconnector. In one or more embodiments of the present invention, thefirst filtration system may comprise a filter configured to filterparticles having a size in a range between 750 microns and 80 microns,the second filtration system may comprise a filter configured to filterparticles having a size in a range between 300 microns and 60 microns,the third filtration system comprises a filter configured to filterparticles having a size in a range between 150 microns and 40 microns,and the fourth filtration system comprises a filter configured to filterparticles having a size smaller than 150 microns or 40 microns.

In one or more embodiments of the present invention, a batch method ofmobile water filtration for on-site decoking operations may includefluidly communicating fluids from a wastewater tank of, for example, amobile decoking system, to an inlet connector of a mobile waterfiltration system. The method may further include monitoring, with acontrol system, a fluid volume of a first tank and a fluid volume of asecond tank of the mobile water filtration system. If the fluid volumeof the first tank is less than a first predetermined volume, the controlsystem may start a first pumping system to fluidly communicate fluidsfrom the inlet connector to the first pumping system, a first filtrationsystem, and the first tank and stopping a second pumping system. If thefluid volume of the first tank reaches a second predetermined volume,the control system may start a coagulant pumping system that fluidlycommunicates a predetermined volume of coagulant from a coagulant tankinto the first tank. If the fluid volume of the first tank reaches athird predetermined volume, the control system may start a flocculantpumping system that fluidly communicates a predetermined volume offlocculant from a flocculant tank into the first tank, pausing for apredetermined amount of time to allow the first tank to settle, and thenstarting the second pumping system to fluidly communicate fluids fromthe first tank to a second filtration system and the second tank. If thefluid volume of the second tank reaches a fourth predetermined volume,the control system may start a third pumping system to fluidlycommunicate fluids from the second tank to a third filtration system, afourth filtration, and an outlet connector. The outlet connector may befluidly connected to a clean water tank of, for example, a mobiledecoking system or to an on-site drain. If the fluid volume of thesecond tank reaches a fifth predetermined volume, the control system maystop the second pumping system.

In one or more embodiments of the present invention, the method mayfurther include monitoring a pressure differential across each of thefirst filtration system, the second filtration system, the thirdfiltration system, and the fourth filtration system. If a pressuredifferential across any filtration system exceeds a predeterminedpressure differential, the control system may stop the pumping systemupstream of the filtration system, allowing an operator to change afilter of the filtration system, and then the control system may restartthe pumping system upstream of the filtration system. In one or moreembodiments of the present invention, the first predetermined volume issmaller than the second predetermined volume, the second predeterminedvolume is smaller than the third predetermined volume, and the fourthpredetermined volume is smaller than the fifth predetermined volume. Incertain embodiments, the first filtration system may comprise a filterfor particles having a size in a range between 750 microns and 80microns, the second filtration system comprises a filter for particleshaving a size in a range between 300 microns and 60 microns, the thirdfiltration system comprises a filter for particles having a size in arange between 150 microns and 40 microns, and the fourth filtrationsystem comprises a filter for particles having a size smaller than 150microns or 40 microns.

In one or more embodiments of the present invention, a continuous methodof mobile water filtration for on-site decoking operations may includefluidly communicating fluids from a wastewater tank of, for example, amobile decoking system, to an inlet connector of a mobile waterfiltration system. The method may further include monitoring, with acontrol system, a fluid volume of a first tank and a fluid volume of asecond tank of the mobile water filtration system. If the fluid volumeof the first tank is less than a first predetermined volume, the controlsystem may start a first pumping system to fluidly communicate fluidsfrom the inlet connector to the first pumping system, a first filtrationsystem, and the first tank and stopping a second pumping system. If thefluid volume of the first tank reaches a second predetermined volume,the control system may start the second pumping system to fluidlycommunicate fluids from the first tank to a second filtration system andthe second tank. If the fluid volume of the second tank reaches a thirdpredetermined volume, the control system may start a third pumpingsystem to fluidly communicate fluids from the second tank to a thirdfiltration system, a fourth filtration, and an outlet connector. Theoutlet connector may be fluidly connected to a clean water tank of, forexample, a mobile decoking system or to an on-site drain. If the fluidvolume of the second tank reaches a fourth predetermined volume, thecontrol system may stop the second pumping system.

In one or more embodiments of the present invention, the method mayfurther include monitoring a pressure differential across each of thefirst filtration system, the second filtration system, the thirdfiltration system, and the fourth filtration system. If a pressuredifferential across any filtration system exceeds a predeterminedpressure differential, the control system may stop the pumping systemupstream of the filtration system, allowing an operator to change afilter of the filtration system, and then the control system may restartthe pumping system upstream of the filtration system. In one or moreembodiments of the present invention, the first predetermined volume maybe smaller than the second predetermined volume and the thirdpredetermined volume may be smaller than the fourth predeterminedvolume. In certain embodiments, the first filtration system may comprisea filter for particles having a size in a range between 750 microns and80 microns, the second filtration system comprises a filter forparticles having a size in a range between 300 microns and 60 microns,the third filtration system comprises a filter for particles having asize in a range between 150 microns and 40 microns, and the fourthfiltration system comprises a filter for particles having a size smallerthan 150 microns or 40 microns.

Advantages of one or more embodiments of the present invention mayinclude one or more of the following:

In one or more embodiments of the present invention, a method and systemfor mobile water filtration enables on-site recycling of wastewater forreuse in, for example, mechanical decoking operations of fired-heaters,furnaces, boilers, or other systems prone to build up of residue orscale.

In one or more embodiments of the present invention, a method and systemfor mobile water filtration enables on-site disposal of wastewater in asafe and environmentally friendly manner.

In one or more embodiments of the present invention, a method and systemfor mobile water filtration uses a coagulant, a flocculant, and aplurality of cascaded filters of increasingly fine pitch to treatwastewater and remove coke particulate matter for reuse or safe andenvironmentally friendly disposal.

In one or more embodiments of the present invention, a method and systemfor mobile water filtration may be operated in an automated manner suchthat its use, in for example, combination with a mobile decoking system,does not require human intervention.

In one or more embodiments of the present invention, a method and systemfor mobile water filtration significantly reduces the volume of sourcewater required for mechanical decoking operations and significantlyreduces the volume of wastewater to be disposed of after completion ofmechanical decoking operations.

In one or more embodiments of the present invention, a method and systemfor mobile water filtration reduces or eliminates the need for treatmentand disposal of contaminated wastewater. The filtered water may bereused for further use or disposed of in a safe and an environmentallyfriendly manner.

In one or more embodiments of the present invention, a method and systemfor mobile water filtration substantially reduces the costs associatedwith sourcing water and disposal of wastewater generated as part ofmechanical decoking operations.

In one or more embodiments of the present invention, a method and systemfor mobile water filtration substantially reduces or eliminates the riskof fouling the environment.

In one or more embodiments of the present invention, a method and systemfor mobile water filtration may be used in furnaces that require sodaash passivation while decoking. Soda ash is typically dissolved in thewater used for decoking. Since the mobile water filtration unit does notfilter out the dissolved soda ash, it is retained for reuse with therecycled water.

In one or more embodiments of the present invention, a method and systemfor mobile water filtration may be scaled up or down based on theapplication. For example, in certain embodiments a standard 40-foottrailer may be used, however, in other embodiments a 48-foot or 53-foottrailer may be used. In such embodiments, the equipment, including thetank sizes and the filtration systems, may scale to make productive useof the additional area. In such cases, the predetermined volumesdescribed herein may scale accordingly.

While the present invention has been described with respect to theabove-noted embodiments, those skilled in the art, having the benefit ofthis disclosure, will recognize that other embodiments may be devisedthat are within the scope of the invention as disclosed herein.Accordingly, the scope of the invention should only be limited by theappended claims.

What is claimed is:
 1. A method of mobile water filtration for on-sitedecoking operations comprising: monitoring a fluid volume of a firsttank and a fluid volume of a second tank; if the fluid volume of thefirst tank is less than a first predetermined volume, starting a firstpumping system to fluidly communicate fluids from an inlet connector tothe first pumping system, a first filtration system, and the first tankand stopping a second pumping system; if the fluid volume of the firsttank reaches a second predetermined volume, fluidly communicating apredetermined volume of coagulant into the first tank; if the fluidvolume of the first tank reaches a third predetermined volume, fluidlycommunicating a predetermined volume of flocculant into the first tank,pausing for a predetermined amount of time to allow the first tank tosettle, and starting the second pumping system to fluidly communicatefluids from the first tank to a second filtration system and the secondtank; if the fluid volume of the second tank reaches a fourthpredetermined volume, starting a third pumping system to fluidlycommunicate fluids from the second tank to a third filtration system, afourth filtration system, and an outlet connector; and if the fluidvolume of the second tank reaches a fifth predetermined volume, stoppingthe second pumping system.
 2. The method of claim 1, further comprising:fluidly communicating fluids from a wastewater tank to the inletconnector.
 3. The method of claim 1, further comprising: fluidlycommunicating fluid from the outlet connector to a clean water tank. 4.The method of claim 1, further comprising: fluidly communicating fluidfrom the outlet connector to an on-site drain.
 5. The method of claim 1,further comprising: monitoring a pressure differential across each ofthe first filtration system, the second filtration system, the thirdfiltration system, and the fourth filtration system; if a pressuredifferential across any filtration system exceeds a predeterminedpressure differential, stopping the pumping system upstream of thefiltration system, changing a filter of the filtration system, andrestarting the pumping system upstream of the filtration system.
 6. Themethod of claim 1, wherein the first predetermined volume is smallerthan the second predetermined volume and the second predetermined volumeis smaller than the third predetermined volume.
 7. The method of claim1, wherein the fourth predetermined volume is smaller than the fifthpredetermined volume.
 8. The method of claim 1, wherein the firstfiltration system comprises a filter for particles having a size in arange between 750 microns and 80 microns.
 9. The method of claim 1,wherein the second filtration system comprises a filter for particleshaving a size in a range between 300 microns and 60 microns.
 10. Themethod of claim 1, wherein the third filtration system comprises afilter for particles having a size in a range between 150 microns and 40microns.
 11. The method of claim 1, wherein the fourth filtration systemcomprises a filter for particles having a size smaller than 150 micronsor 40 microns.
 12. The method of claim 1, wherein a wastewater tank of adecoking system is fluidly connected to the inlet connector and theoutlet connector is fluidly connected to a clean water tank of thedecoking system.